Thermosetting resin composition for high performance laminates
View Patent ↗This invention concerns a thermosetting resin system that is useful in the manufacture of high performance prepreg, laminate and composite materials as well as the prepregs, laminates and composites made from the thermosetting resin composition.
1. A thermosetting resin composition comprising:
at least one elastomer;
at least one polyester; and
at least one flame retardant,
wherein the at least one elastomer is selected from the group consisting of a styrene-butadiene-divinylbenzene terpolymer, a maleinized polybutadiene styrene copolymer, and mixtures thereof, and wherein total polyester content of the thermosetting resin composition is from about 1 wt % to about 15 wt % as a percentage of the composition solids content.
2. The composition of claim 1 wherein the at least one elastomer comprises from about 20 wt % to about 60 wt %; and the at least one flame retardant comprises from about 5 wt % to about 50 wt %, each as a percentage of the composition solids content.
3. The composition of claim 1 wherein the at least one polyester is an unsaturated polyester.
4. The composition of claim 1 further comprising at least one catalyst.
5. The composition of claim 4 wherein the at least one catalyst is a peroxide catalyst.
6. The composition of claim 5 wherein the at least one catalyst is selected from dicumyl peroxide, tert-butyl peroxbenzoate, and mixtures thereof.
7. The composition of claim 4 wherein the at least one catalyst comprises about 2 wt % to about 8 wt % as a percentage of the composition solids content.
8. The composition of claim 1 further comprising at least one filler selected from the group consisting of PTFE fluoropolymer resin, talc, quartz, ceramics, particulate metal oxides, silica, titanium dioxide, alumina, ceria, clay, boron nitride, wollastonite, and mixtures thereof.
9. The composition of claim 8 wherein the filler comprises about 5% to about 40% as a percentage of the composition solids content.
10. The composition of claim 8 wherein the filler is silane treated fused silica.
11. The composition of claim 1 wherein the at least one flame retardant is decabromodiphenylethane.
12. The composition of claim 1 wherein the elastomer comprises from about 20 wt % to about 60 wt % as a percentage of the composition solids content.
13. A thermosetting resin composition comprising:
a polybutadiene styrene divinylbenzene terpolymer;
an unsaturated polyester;
decabromodiphenylethane;
fused silica; and
dicumyl peroxide,
wherein total polyester content of the thermosetting resin composition is from about 1 wt % to about 15 wt % as a percentage of the composition solids content.
14. The composition of claim 13 wherein the terpolymer comprises from about 30 wt % to about 35 wt %; the decabromodiphenylethane comprises from about 20 wt % to about 25 wt %; the fused silica comprises from about 32 wt % to about 38 wt %; and the dicumyl peroxide comprises from about 5 wt % to about 6 wt %, each as a percentage of the composition solids content.
15. A prepreg comprising a thermosetting resin composition and a core material, wherein the thermosetting resin composition comprises:
at least one elastomer;
at least one polyester; and
at least one flame retardant,
wherein the at least one elastomer is selected from the group consisting of a styrene-butadiene-divinylbenzene terpolymer, a maleinized polybutadiene styrene copolymer, and mixtures thereof, and wherein total polyester content of the thermosetting resin composition is from about 1 wt % to about 15 wt % as a percentage of the composition solids content.
16. The prepreg of claim 15 wherein the at least one elastomer comprises from about 20 wt % to about 60 wt %; and the at least one flame retardant comprises from about 5 wt % to about 50 wt %, each as a percentage of the composition solids content.
17. The prepreg of claim 15 wherein the at least one polyester is an unsaturated polyester.
18. The prepreg of claim 15 wherein the thermosetting resin composition further comprises at least one catalyst.
19. The prepreg of claim 18 wherein the at least one catalyst is a peroxide catalyst.
20. The prepreg of claim 19 wherein the at least one catalyst is selected from dicumyl peroxide, tert-butyl peroxbenzoate, and mixtures thereof.
21. The prepreg of claim 18 wherein the at least one catalyst comprises about 2 wt % to about 8 wt % as a percentage of the composition solids content.
22. The prepreg of claim 15 wherein the thermosetting resin composition further comprises at least one filler selected from the group consisting of PTFE fluoropolymer resin, talc, quartz, ceramics, particulate metal oxides, silica, titanium dioxide, alumina, ceria, clay, boron nitride, wollastonite, and mixtures thereof.
23. The prepreg of claim 22 wherein the filler comprises about 5% to about 40% as a percentage of the composition solids content.
24. The prepreg of claim 22 wherein the filler is silane treated fused silica.
25. The prepreg of claim 15 wherein the core material comprises a woven glass web.
26. The prepreg of claim 15 wherein the at least one flame retardant is decabromodiphenylethane.
27. A prepreg comprising a thermosetting resin composition and a core material, wherein the thermosetting resin composition comprises:
a polybutadiene styrene divinylbenzene terpolymer;
an unsaturated polyester;
decabromodiphenylethane;
fused silica; and
dicumyl peroxide
wherein total polyester content of the thermosetting resin composition is from about 1 wt % to about 15 wt % as a percentage of the composition solids content.
28. The prepreg of claim 27 wherein the core material comprises a woven glass web.
29. A laminate comprising one or more prepregs and one or more sheets of conducting foil, wherein the one or more prepregs comprises a thermosetting resin composition and a core material, and wherein the thermosetting resin composition comprises: at least one elastomer; at least one polyester; and at least one flame retardant, wherein the at least one elastomer is selected from the group consisting of a styrene-butadiene-divinylbenzene terpolymer, a maleinized polybutadiene styrene copolymer, and mixtures thereof, and wherein total polyester content of the thermosetting resin composition is from about 1 wt % to about 15 wt % as a percentage of the composition solids content.
30. The laminate of claim 29 wherein the one or more prepregs and the one or more sheets of conducting foil are alternately stacked.
31. The laminate of claim 29 wherein in the thermosetting resin composition, the at least one elastomer comprises from about 20 wt % to about 60 wt %; and the at least one flame retardant comprises from about 5 wt % to about 50 wt %, each as a percentage of the composition solids content.
32. The laminate of claim 29 wherein the at least one polyester is an unsaturated polyester.
33. The laminate of claim 29 wherein the thermosetting resin composition further comprises at least one catalyst.
34. The laminate of claim 33 wherein the at least one catalyst is a peroxide catalyst.
35. The laminate of claim 34 wherein the at least one catalyst is selected from dicumyl peroxide, tertbutyl peroxbenzoate, and mixtures thereof.
36. The laminate of claim 33 wherein the at least one catalyst comprises about 2 wt % to about 8 wt % as a percentage of the composition solids content.
37. The laminate of claim 29 wherein the thermosetting resin composition further comprises at least one tiller selected from the group consisting of PTFE fluoropolymer resin, talc, quartz, ceramics, particulate metal oxides, silica, titanium dioxide, alumina, ceria, clay, boron nitride, wollastonite, and mixtures thereof.
38. The laminate of claim 37 wherein the filler comprises about 5% to about 40% as a percentage of the composition solids content.
39. The laminate of claim 37 wherein the filler is silane treated fused silica.
40. The laminate of claim 29 wherein the one or more sheets of conducting foil are copper foil.
41. The laminate of claim 29 wherein the at least one flame retardant is decabromodiphenylethane.
42. A laminate comprising one or more prepregs and one or more sheets of conducting foil, wherein the one or more prepregs comprises a thermosetting resin composition and a core material, and wherein the thermosetting resin composition comprises: a polybutadiene styrene divinylbenzene terpolymer; an unsaturated polyester; decabromodiphenylethane; fused silica; and dicumyl peroxide, and wherein total polyester content of the thermosetting resin composition is from about 1 wt % to about 15 wt % as a percentage of the composition solids content.